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rotary kiln design calculations in sponge iron plant

SPONGE IRON PLANT

Sponge iron being magnetic gets attracted and gets separated from non- magnetic char. The iron ore and coal crushed and screened to respective sizes are fed to rotary kiln through feed tube in pre-determined ratio. The rotary kiln is slightly inclined at an angle 2.5 deg and rotated by

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Computational fluid dynamics analysis of sponge iron

Mar 01, 2017· However, very little work is available related to CFD analysis of rotary kiln of sponge iron process such as: Prasad and Ray developed 2D model to simulate flow pattern of air in rotary kiln of a typical 100 tpd sponge iron plant. They considered different positions of air pipe such as 50 mm, 100 mm, 150 mm and 320 mm above the axis for

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OPERATIONAL ASPECTS OF SPONGE IRON PRODUCTION IN

1. Krupp Sponge Iron Process The Krupp. Sponge iron process uses a rotary kiln for the reduction of high grade lump ores or pellets (Fig. 1). The feed is introduced together with reducing and de-sulphurizing agents (lime-stone or raw dolomite) into an inclined rotary kiln, heated counter current to the flow of hot gas and reduced to form sponge

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Modelling and optimization of a rotary kiln direct

large number of viable design and operating candidates. Introduction Rotary kilns (Figure 1) are used for a range of mineral processing operations. Kilns range in size from 2–6 m in diameter and can be 50–225 m long with an operating mass of up to 3000 t. Two of the most common applications are for cement production and sponge iron production.

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Accretion Control in Sponge Iron Production Kiln using

This study focuses on sponge iron kiln based process. The chemical process involved in making sponge iron removes oxygen from iron ore by using a reducing agent in the form of non-coking coal [Patra et al, (2005)]. The reduction process is carried out in an inclined horizontal rotary kiln, which rotates at a programmed speed.

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Sponge Iron Plant Complete Project & Equipment Technical

Jan 26, 2020· Sponge iron plant rotary kiln and cooler list of machinery spare parts and casting and forging technical procurement specifications budgetary cost for coal based, gas based, electric based sponge iron plant for 50 TPD, 75 TPD, 100 TPD, 150 TPD, 175 TPD, 200 TPD, 300 TPD, 350 TPD, 500 TPD, 600 TPD (Tons per day).

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Coal & Gas based DRI Plant Rotary Kiln for Making Sponge

We manufacture Sponge Iron Plant on turn-key basis of different functional capacities i.e. 100 TPD, 300 TPD, 500 TPD plants.The equipment support provided for the plants include Kiln/cooler tyre, Kiln/cooler support roller, Kiln/cooler support roller shaft, Kiln/cooler support roller assembly with bearing housing, Kiln/cooler girth gear, Kiln/cooler pinions, Kiln/cooler pinion shaft, Kiln

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DESIGN OF WASTE HEAT RECOVERY SYSTEM IN A SPONGE

The waste gas from a sponge iron plant exits at a temperature of around 200-300 C. A lot of sensible heat is lost with these gases. This heat is utilized to preheat the air entering to kiln. Further, the waste gas at reduced temperature is used to cool hot sponge iron which is previously carried out by water.

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Coal based Direct Reduction Rotary Kiln Process IspatGuru

Boudouard reaction, dolomite, DRI, Iron ore, metallization, non coking coal, pellets, reduction, Rotary kiln, Sponge iron, Sulphur, Coal based Direct Reduction Rotary Kiln Process . The coal based direct reduction rotary kiln process was developed for converting iron ore directly into metallic iron without the melting of the materials.

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(PDF) Operability Analysis of Direct Reduction of Iron Ore

The results showed that the rotary kiln could be divided into three major functional zones: reduction of hematite to wüstite occurred at 1023–1163 K; wüstite transformed to fine metallic iron

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Computational fluid dynamics analysis of sponge iron

Mar 01, 2017· However, very little work is available related to CFD analysis of rotary kiln of sponge iron process such as: Prasad and Ray developed 2D model to simulate flow pattern of air in rotary kiln of a typical 100 tpd sponge iron plant. They considered different positions of air pipe such as 50 mm, 100 mm, 150 mm and 320 mm above the axis for

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2 D Model of Sponge Iron Rotary Kiln Developed Using CFD

2II. Rotary kiln: Operation and construction details A schematic diagram of the rotary kiln of sponge iron process considered for the present work is shown in Fig. 1. The rotary kiln consists of a rotating cylindrical shell lined inside with refractory material. The kiln is around 80 m long with 4 m

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Sponge Iron Production in Rotary Kiln Arabinda Sarangi

The entire rotary kiln plant and its functionalities are explained with precision. The concluding chapters explicate the ways to store and handle sponge iron. The heat and mass balance calculation done meticulously shows how the waste heat can be utilised for power generation.

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calculation on reduction for direct reduced iron in tunnel

sponge iron production from ore -coal composite pellets in tunnel kiln. Keywords: Tunnel Kiln, Iron ore-coal composite pellets, Sponge iron, Thermal efficiency, products [1-2]. In the year 1908 use of tunnel kiln started for iron oxide reduction. This . For composite pellets amount of external coal is

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New Concept of Hot Metal Production using Rotary Kiln

The idea of this technology is to utilize the heat or energy contained in sponge iron (temperature of sponge iron > 1000 o C) at the end of rotary kiln before it is cooled by rotary cooler to

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Energy survey of the coal based sponge iron industry

Sep 01, 2015· In conventional coal based sponge iron plant, Fig. 1, kiln feed (Stream no. 1), which consists of iron ore, feed coal and dolomite, is fed to the rotary kiln (RK).A separate conveyor collects different size fractions of coal (Stream no. 5) for injection into the kiln with the help of pressurized air (Stream no. 4) from discharge end side.

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THE KRUPP SPONGE IRON PROCESS PRODUCTION AND

period during which sponge iron was continu-ously produced on a commercial scale. The tests again confirmed that semi-commercial tests car-ried out in the existing rotary kiln pilot plant furnish reliable design data as well as process characteristics for treating the raw materials in a commercial operation. The pilot plant today

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A Thesis Submitted for Partial Fulfillment of the Degree

3.3 Schematic of optimised Rotary kiln sponge iron making process 21 4.1 Industrial view of Sponge Iron making Rotary Kiln 24 4.2 Schematic view of internal heat exchange in Rotary kiln 26 4.3 Schematic view of Lobe Blower. 27 4.4 Schematic view of Air & material flow in Rotary kiln 27 4.5 Filling of Bed Geometry 28

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DRI UPDATE Sponge Iron Manufacturer India

2. ED, SIMA requested the participants to volunteer to spare their rotary kiln for carrying out the R&D for exploring the use of Syn Gas in the rotary kiln. Mr. T Srinivasa Rao, MD, Balajiswamy Premium Steels Pvt Ltd offered his 50TPD kiln for this purpose. 3. Presentation from Tata Sponge Iron Ltd was very much liked and lot of the people showed

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FUTURE OF SPONGE IRON IN INDIA AND PLANT DESIGN

producing sponge iron at low price. For the proper design of such a Rotary Kiln and Cooler with all its ancillaries, the following metallurgical and engineering de-sign. data is required to be followed for a 50 Ton per day experimental sponge iron plant, which would form the main guide lines for the designers lof industrial size plants in the near

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Rotary Kiln Electrotherm Engineering & Technologies

Coal Based Rotary Kiln for Direct Reduced Iron / Sponge Iron (100 TPD, 350 TPD, 500 TPD) Solid state reduction of Iron Ore using either coal/gas as a medium of reduction to produce a substitute raw material for steel making is termed as Direct Reduced Iron (DRI).

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heat calculation in rotary kiln

Rotary Kiln Design Calculations. Rotary kiln design sizing selection calculations BINQ · Rotary kiln technologies Our crusher. Our crusher Minerals designs and supplies both direct fired and indirect fired rotary kilns for a wide time in the kiln is an important design

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CLEAN DEVELOPMENT MECHANISM PROJECT DESIGN

The ASL Sponge Iron unit at present consists of one rotary kiln of 500 TPD and the flue gas generated from the kiln is about 120,000 Nm3/hr at 950-10000C. Flue gas with high heat content is generated in the Rotary kiln in the Sponge iron plant during conversion of Iron Ore into Sponge Iron. The entire

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Sponge Iron Dolomite Aluminium Oxide Mini Cement Plant

Sponge Iron Dolomite Aluminium Oxide Mini Cement Plant Rotary Kiln,Find Complete Details about Sponge Iron Dolomite Aluminium Oxide Mini Cement Plant Rotary Kiln,High Quality Rotary Kiln,Mini Cement Kiln,Sponge Iron Kiln from Cement Making Machinery Supplier or Manufacturer-Henan Sunstrike Machinery & Equipment Co., Ltd.

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